MX2014000811A - Substrate for wallboard joint tape and process for making same. - Google Patents
Substrate for wallboard joint tape and process for making same.Info
- Publication number
- MX2014000811A MX2014000811A MX2014000811A MX2014000811A MX2014000811A MX 2014000811 A MX2014000811 A MX 2014000811A MX 2014000811 A MX2014000811 A MX 2014000811A MX 2014000811 A MX2014000811 A MX 2014000811A MX 2014000811 A MX2014000811 A MX 2014000811A
- Authority
- MX
- Mexico
- Prior art keywords
- layer
- paper substrate
- measured
- tappi
- layers
- Prior art date
Links
Classifications
-
- D—TEXTILES; PAPER
- D21—PAPER-MAKING; PRODUCTION OF CELLULOSE
- D21H—PULP COMPOSITIONS; PREPARATION THEREOF NOT COVERED BY SUBCLASSES D21C OR D21D; IMPREGNATING OR COATING OF PAPER; TREATMENT OF FINISHED PAPER NOT COVERED BY CLASS B31 OR SUBCLASS D21G; PAPER NOT OTHERWISE PROVIDED FOR
- D21H27/00—Special paper not otherwise provided for, e.g. made by multi-step processes
- D21H27/30—Multi-ply
- D21H27/38—Multi-ply at least one of the sheets having a fibrous composition differing from that of other sheets
-
- D—TEXTILES; PAPER
- D21—PAPER-MAKING; PRODUCTION OF CELLULOSE
- D21H—PULP COMPOSITIONS; PREPARATION THEREOF NOT COVERED BY SUBCLASSES D21C OR D21D; IMPREGNATING OR COATING OF PAPER; TREATMENT OF FINISHED PAPER NOT COVERED BY CLASS B31 OR SUBCLASS D21G; PAPER NOT OTHERWISE PROVIDED FOR
- D21H27/00—Special paper not otherwise provided for, e.g. made by multi-step processes
- D21H27/30—Multi-ply
- D21H27/32—Multi-ply with materials applied between the sheets
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B32—LAYERED PRODUCTS
- B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
- B32B29/00—Layered products comprising a layer of paper or cardboard
- B32B29/002—Layered products comprising a layer of paper or cardboard as the main or only constituent of a layer, which is next to another layer of the same or of a different material
- B32B29/005—Layered products comprising a layer of paper or cardboard as the main or only constituent of a layer, which is next to another layer of the same or of a different material next to another layer of paper or cardboard layer
-
- D—TEXTILES; PAPER
- D21—PAPER-MAKING; PRODUCTION OF CELLULOSE
- D21H—PULP COMPOSITIONS; PREPARATION THEREOF NOT COVERED BY SUBCLASSES D21C OR D21D; IMPREGNATING OR COATING OF PAPER; TREATMENT OF FINISHED PAPER NOT COVERED BY CLASS B31 OR SUBCLASS D21G; PAPER NOT OTHERWISE PROVIDED FOR
- D21H11/00—Pulp or paper, comprising cellulose or lignocellulose fibres of natural origin only
-
- D—TEXTILES; PAPER
- D21—PAPER-MAKING; PRODUCTION OF CELLULOSE
- D21H—PULP COMPOSITIONS; PREPARATION THEREOF NOT COVERED BY SUBCLASSES D21C OR D21D; IMPREGNATING OR COATING OF PAPER; TREATMENT OF FINISHED PAPER NOT COVERED BY CLASS B31 OR SUBCLASS D21G; PAPER NOT OTHERWISE PROVIDED FOR
- D21H25/00—After-treatment of paper not provided for in groups D21H17/00 - D21H23/00
- D21H25/04—Physical treatment, e.g. heating, irradiating
-
- E—FIXED CONSTRUCTIONS
- E04—BUILDING
- E04F—FINISHING WORK ON BUILDINGS, e.g. STAIRS, FLOORS
- E04F13/00—Coverings or linings, e.g. for walls or ceilings
- E04F13/02—Coverings or linings, e.g. for walls or ceilings of plastic materials hardening after applying, e.g. plaster
- E04F13/04—Bases for plaster
- E04F13/042—Joint tapes
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
- B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
- B29C65/00—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor
- B29C65/48—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor using adhesives, i.e. using supplementary joining material; solvent bonding
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B32—LAYERED PRODUCTS
- B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
- B32B7/00—Layered products characterised by the relation between layers; Layered products characterised by the relative orientation of features between layers, or by the relative values of a measurable parameter between layers, i.e. products comprising layers having different physical, chemical or physicochemical properties; Layered products characterised by the interconnection of layers
- B32B7/02—Physical, chemical or physicochemical properties
-
- D—TEXTILES; PAPER
- D21—PAPER-MAKING; PRODUCTION OF CELLULOSE
- D21H—PULP COMPOSITIONS; PREPARATION THEREOF NOT COVERED BY SUBCLASSES D21C OR D21D; IMPREGNATING OR COATING OF PAPER; TREATMENT OF FINISHED PAPER NOT COVERED BY CLASS B31 OR SUBCLASS D21G; PAPER NOT OTHERWISE PROVIDED FOR
- D21H27/00—Special paper not otherwise provided for, e.g. made by multi-step processes
- D21H27/18—Paper- or board-based structures for surface covering
- D21H27/20—Flexible structures being applied by the user, e.g. wallpaper
-
- Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
- Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
- Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
- Y10T156/00—Adhesive bonding and miscellaneous chemical manufacture
- Y10T156/10—Methods of surface bonding and/or assembly therefor
-
- Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
- Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
- Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
- Y10T428/00—Stock material or miscellaneous articles
- Y10T428/24—Structurally defined web or sheet [e.g., overall dimension, etc.]
- Y10T428/24942—Structurally defined web or sheet [e.g., overall dimension, etc.] including components having same physical characteristic in differing degree
-
- Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
- Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
- Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
- Y10T428/00—Stock material or miscellaneous articles
- Y10T428/24—Structurally defined web or sheet [e.g., overall dimension, etc.]
- Y10T428/24942—Structurally defined web or sheet [e.g., overall dimension, etc.] including components having same physical characteristic in differing degree
- Y10T428/24983—Hardness
Landscapes
- Engineering & Computer Science (AREA)
- Architecture (AREA)
- Civil Engineering (AREA)
- Structural Engineering (AREA)
- Paper (AREA)
- Laminated Bodies (AREA)
Abstract
A multi-ply paper substrate is provided, which comprises at least two plies bonded to one another by an adhesive; a basis weight of 80-200 gsm; an internal bond of 10-180 milli-ft.-lb/sq. in. as measured by TAPPI method 541; an MD tensile of 20-300 lbf/inch width as measured by TAPPI method 494; and a CD tensile of 10-300 lbf/inch width as measured by TAPPI method 494. Methods of making and using the paper substrate, products made therefrom, and uses of the paper substrate are also provided.
Description
SUBSTRATE OF TAPE FOR JOINTS OF PLASTER PANELS AND THE PROCESS TO MAKE THE SAME BACKGROUND
Field of the Invention
The invention relates to a tape substrate for joints of gypsum panels, products made therefrom and to processes for production and use.
BRIEF DESCRIPTION OF THE FIGURES
Various modalities are described in conjunction with the accompanying figures, which are not intended to be limiting, unless otherwise specified.
Figure 1 shows a cross-sectional view of a conventional single-layer substrate of gypsum board tape.
Figure 2 shows a cross-sectional view of an example of a multilayer paper substrate.
Figure 3 shows a cross-sectional view of another example of a multilayer paper substrate. In the modality shown, the elements of drawing 1-5 correspond to the items in description 1-5.
Figure 4 shows a cross-sectional view of an example of a multilayer paper substrate. In the modality shown, the elements of drawing 1-4 correspond to the items in description 1-4.
Figure 5 shows a cross-sectional view of an example of a multilayer paper substrate wherein the attached layers are separated for clarity.
Figure 6 shows a diagram of one embodiment of a papermaking machine by air.
Figure 7 shows a diagram of a modality of an airway entry box detail.
DETAILED DESCRIPTION OF THE VARIOUS MODALITIES
One embodiment of the material claimed herein provides a suitable tape product for next-generation gypsum board joins and a process for making the same. A material advantage claimed herein is that the internal resistance (for example in the z-direction) of the drywall tape is decoupled from the resistance in the plane (for example the machine direction) (MD = Machine Direction ) and the cross machine direction (CD = Cross-Machine)). Another advantage of the material claimed here is that the product has a low internal resistance, however controllable and a high tensile strength in the plane. Another advantage of the material claimed here is that the sides of the surface can be adjusted to the extent, so that a robust fluff can be generated with little or no sanding, thus conserving energy, increasing the useful life
of the sandpaper, and creating a surface capable of joining what has not previously been possible. Another advantage is the achievement of a multi-layer paper substrate and tape for drywall joints that have different and optimized layers, which to date have eluded the manufacturers of tape for joints of gypsum board and / or substrates of multilayer paper.
One embodiment of the subject claimed herein provides a multilayer paper substrate, comprising:
at least two layers joined together by an adhesive; a base weight of 80-200 gsm (grams per square meter); an internal junction of 0.0689-1.24 lxlO "3 MPa (10-180 milli-ft-lb / sq in) as measured by the TAPPI 541 method;
an MD tensile strength of 2.26-33,895 N-m (20-300 lbf / in) as measured by the TAPPI 494 method; Y
a CD tensile strength of 1.13-33.895 N-m (10-300 lbf / in) as measured by the TAPPI 494 method.
As used herein, the term "layer" or "layers" refers to a layer or more of a layer of the substrate. The layer may be joined on one or both sides by adhesive, binder or other layers. A given layer can have the same or substantially the same composition through its thickness (ie, the distance between one side and the opposite side) or it can have a varying composition gradient.
about the thickness.
As used herein, the term "side" or "sides" refers to the broad surfaces or interfaces of any substrate, layer, adhesive (e.g., "adhesive region" or tape for drywall joints) of the "edge" or "edges" of the same.For example, when the tape to join drywall is applied on a board of gypsum board, one side of the tape, ie the "wall side" is put in contact with the drywall; and the other side of the belt, ie the "working side" can remain exposed until it is put in contact with the compound for joining gypsum panels, on occasion referred to as "mud" of drywall. In the event that a repair to the plasterboard thus bonded or tape is necessary, the tape can be detached by the installer, ie the tape is peeled off to form two new sides, one of which - on the newly exposed surface of That part of the tape remains on the wall - it can be a new side of work. That part of the tape that falls off can be discarded or reused as appropriate.
The multilayer paper substrate comprises at least two layers bonded together by an adhesive. In a cross-sectional view of the multilayer paper substrate, the adhesive may appear, for example by staining and microscopic examination, as a distinct region,
distinguishable from the two layers attached in composition or other property; or it can be indistinguishable in cross section from the adjoining layers, for example in the case where the adhesive not only joins the two adjacent layers together, but also permeates each layer and acting as a binder, provides internal bonding for all or a portion of one or both of the layers. In one embodiment, the respective layers may have the same or different compositions, thickness and / or properties. In one embodiment, the layers are produced in an airway papermaking process. In one embodiment, two adjoining layers interpenetrate each other in the adhesive bond region. In another embodiment, two adjoining layers partially interpenetrate each other in the adhesive bond region. In another embodiment, two adjoining layers do not interpenetrate in fact, being separated from each other by an intermediate or interspersed adhesive bond region. In one embodiment, the adhesive region is not considered a distinct layer.
The multilayer paper substrate has a basis weight of 80-200 gsm. This range includes all the values and subintervals between them, including 80, 90, 100, 110, 120, 130, 140, 150, 160, 170, 180, 190, and 200 gsm. In one embodiment, the basis weight of one layer or more than one layer may be less than 80 gsm, as long as the multilayer paper substrate has a basis weight of 80-200 gsm. Base weight and
Its size is known to those with ordinary skill in papermaking technique.
The multi-layer paper substrate has an internal bond (CD or MD) of 0.0689-1.241x10 ~ 3 MPa (10-180 milli-ft-lb / sq in) as measured by the TAPPI 541 method. This range includes all the values and subintervals among them including 0.069xl0 ~ 3, 0.138xl0 ~ 3, 0.207xl0 ~ 3, 0.276x10"3, 0.345xl0 ~ 3, 0.414xl0 ~ 3, 0.483xl0 ~ 3, 0.552xl0 ~ 3,
0. 621xl0 ~ 3, 0.689xl0 ~ 3, 0.758xl0"3, 0.827xl0 ~ 3,
0. 896xl0 ~ 3, 0.965xl0 ~ 3, 1.034xl0 ~ 3, 1.103xl0 ~ 3,
1. 172xl0"3 and 0.0689-1.241xl0" 3 MPa (10, 20, 30, 40, 50, 60, 70, 80, 90, 100, 110, 120, 130, 140, 150, 160, 170, and 180 milli- ft. -lb / sq. in). The measurement is carried out according to the known TAPPI method 541, incorporated herein by reference. In one embodiment, one layer or more of a layer on the multilayer paper substrate may have an internal bond of 0.0689-1.24 lxlO "3 MPa (10-180 milli-ft-lb / sq in.) In another embodiment, The adhesive bonding two layers together can result in an internal bond of 0.0689-1.241xl0"3 MPa (10-180 milli-ft-lb / sq in) for the multilayer paper substrate. In another embodiment, a combination of one or more layers of adhesive can result in an internal bond of 0.0689-1.241x10 ~ 3 MPa (10-180 milli-ft-lb / sq in) for the multilayer paper substrate. In a modality, the internal union of a layer or more than one layer, the
adhesive bonding to two joined layers or a combination thereof may be greater than 1,241xl0 ~ 3 MPa (180 milli-ft-lb / sq in) as long as the multilayer paper substrate has an internal bond of 0.0689-1.241 xl0 ~ 3 MPa (10-180 milli-ft-lb / sq in).
The multilayer paper substrate has an MD tensile strength of 2.26-33,895 Nm (20-300 lbf / in) as measured by the TAPPI 494 method. This range includes all values and subintervals including 2,260, 3,389, 4,519, 5,649, 6,779, 7,909, 9,038, 10,168, 11,298, 12,428, 13,558, 14,687, 15,817, 16,947, 18,077, 19,207, 20,336, 21,466, 22,596, 23,726, 24,856, 25,985, 27,115, 28,245, 29,375, and 30,505. 31,634, 32,764, 33,895 Nm (20, 30, 40, 50, 60, 70, 80, 90, 100, 110, 120, 130, 140, 150, 160, 170, 180, 190, 200, 210, 220, 230 , 240, 250, 260, 270, 280, 290, and 300 lbf / in) in width. The measurement is carried out according to the known TAPPI 494 method, incorporated here by reference. In one embodiment, one layer or more of a layer in the multilayer paper substrate can have an MD tensile strength of 2.26-33,895 N-m (20-300 lbf / in) in width. In one embodiment, the tensile strength MD of one layer or more than one layer can be 0-33,895 Nm (20-300 lbf / in) in width as long as the multilayer paper substrate has an MD tensile strength. 2.26-33.895 Nm (20-300 lbf / in) wide.
The CD multi-layer paper substrate has a tensile strength of 1.13-33.895 Nm (10-300 lbf / in) wide as measured by the TAPPI 494 method. This range includes all intermediate values and subintervals including 1.13, 2,260, 3,389, 4,519, 5,649, 6,779, 7,909, 9,038, 10,168, 11,298, 12,428, 13,558, 14,687, 15,817, 16,947, 18,077, 19,207, 20,336, 21,466, 22,596, 23,726, 24,856, 25,985, 27,115, 28,245, 29,375, 30,505, 31,634, 32,764, 33,895 Nm (20, 30, 40, 50, 60, 70, 80, 90, 100, 110, 120, 130, 140, 150, 160, 170, 180, 190, 200, 210, 220 , 230, 240, 250, 260, 270, 280, 290, and 300 lbf / in) in width. The measurement is carried out according to the known method TAPPI 494, incorporated herein by reference. In one embodiment, one layer or more than one layer in the multilayer paper substrate can have a CD tensile strength of 1.13-33.895 N-m (10-300 lbf / in) in width. In one embodiment, the CD tensile strength of one layer or more than one layer can be 0-33,895 Nm (0-300 lbf / in) in width as long as the multilayer paper substrate has a CD tensile strength. of 1.13-33.895 Nm (10-300 lbf / in) in width.
In one embodiment, one or more layers of the multilayer paper substrate have:
an MD tensile strength of 2.26-33.895 N-m (20-300 lbf / in) in width as measured by the TAPPI 494 method; Y
a CD tensile strength of 1.13-33.895 N-m (10-300 lbf / in) in width, as measured by the TAPPI 494 method.
In one embodiment, tensile strengths CD and D of the multilayer paper substrate are equal to each other. In one embodiment, the CD and MD tensile strengths of one layer are equal to each other. When the tensile strength MD and the tensile strength CD are equal to each other, the range is not particularly limited. In one embodiment, the tensile strengths MD and CD are equal and may be in the range of 2.26-33.895 N-m (20-300 lbf / in) in width. This range includes all intermediate values and subintervals, including 2,260, 3,389, 4,519, 5,649, 6,779, 7,909, 9,038, 10,168, 11,298, 12,428, 13,558, 14,687, 15,817, 16,947, 18,077, 19,207, 20,336, 21,466, 22,596, 23,726 , 24,856, 25,985, 27,115, 28,245, 29,375, 30,505, 31,634, 32,764, 33,895 Nm (20, 30, 40, 50, 60, 70, 80, 90, 100, 110, 120, 130, 140, 150, 160, 170, 180, 190, 200, 210, 220, 230, 240, 250, 260, 270, 280, 290, and 300 lbf / in) in width as measured by the TAPPI method 494.
Although not particularly limited, in one embodiment, a single layer can have an internal bond of 0.0689-1.241xl0"3 MPa (10-180 milli-ft-lb / sq in) as measured by the TAPPI 541 method. It will include all values and sub-ranges among them including 0.069x10, 0.138xl0"3, 0.207xl0 ~ 3, 0.276xl0" 3, 0.345xl0 ~ 3, 0.414x10"
3, 0.483xl0 ~ 3, 0.552xl0 ~ 3, 0.621xl0 ~ 3, 0.689xl0"3,
0. 758xl0 ~ 3, 0.827xl0 ~ 3, 0.896xl0 ~ 3, 0.965xl0 ~ 3, 1.034x
10 ~ 3, 1.103xl0 ~ 3, 1.172xl0 ~ 3 and 0.0689-1.241xl0 ~ 3 MPa (10, 20, 30, 40, 50, 60, 70, 80, 90, 100, 110, 120, 130, 140, 150, 160, 170, and 180 milli-ft. -lb / sq. In).
Although not particularly limited in one embodiment, the adhesive bonding to two adjoining layers may be in the form of an adhesive layer or an adhesive region between the two layers, at the interface of the two layers, interpenetrating one or both of the layers. two layers, or a combination thereof. In another embodiment, the adhesive may have an internal bond of 0.0689-1.241x10 ~ 3 MPa (10-180 milli-ft-lb / sq in) as measured by the TAPPI 541 method. This range includes all values and sub-ranges between they including 0.069xl0"3, 0.138xl0 ~ 3, 0.207xl0" 3, 0.276xl0"3, 0.345xl0 ~ 3, 0.414 x 10" 3, 0.483xl0"3, 0.552xl0" 3, 0.621xl0"3, 0.689xl0"3, 0.758xl0 ~ 3, 0.827xl0" 3, 0.896xl0"3, 0.965xl0 ~ 3, 1.034x
10 ~ 3, 1.103xl0 ~ 3, 1.172xl0"3 and 0.0689-1.241xl0" 3 MPa (10, 20, 30, 40, 50, 60, 70, 80, 90, 100, 110, 120, 130, 140, 150, 160, 170, and 180 milli-ft. -lb / sq. In).
Provided that one or two or more layers here together, the adhesive is not particularly limited. It may include starch, cooked starch, adhesive starch, fibers, bicomponent fibers, cellulose fibers, synthetic fibers, binder or any combination thereof.
Although not particularly limited, the adhesive may be present in one or more of the adhesive regions in an amount of 0.05-10 gsm. This range includes all values and subintervals including 0.05, 0.06, 0.07, 0.08, 0.09, 0.1, 0.2, 0.3, 0.4, 0.5, 0.6, 0.7, 0.8, 0.9, 1, 2, 3, 4, 5, 6 , 7, 8, 9, and 10 gsm.
In one embodiment, wherein the adhesive includes bicomponent fibers and the layer or layers include cellulose fibers, the amount of adhesive for interlayer bonding can be in a range from 0.5-10 gsm of adhesive, this range includes all values and sub-ranges between they, including 0.5, 0.6, 0.7, 0.8, 0.9, 1, 2, 3, 4, 5, 6, 7, 8, 9, and 10 gsm. In another embodiment, wherein the adhesive includes bicomponent fibers and the layer or layers include cellulose fibers, the amount of adhesive for intralayer bonding can be in the range of 2-100% by weight of the finished layer, this range includes all the values and subintervals among them, including 2, 3, 4, 5, 6, 7, 8, 9, 10, 15, 20, 25, 30, 35, 40, 45, 50, 60, 70, 80, 90, 95 , 99, and 100% by weight of the finished layer.
In another embodiment, the adhesive, one or more bonded layers or both the adhesive and one or more attached layers may have an internal bond or joints of 0.0689-1.241xl0"3 MPa (10-180 milli-ft-lb / sq in) as measured by the TAPPI 541 method. This interval includes all values and subranges between
they including 0.069xl0 ~ 3, 0.138xl0 ~ 3, 0.207xl0 ~ 3, 0.276xl0 ~ 3, 0.345xl0 ~ 3, 0.414 x 10 ~ 3, 0.483xl0 ~ 3, 0.552xl0 ~ 3, 0.621xl0 ~ 3, 0.689xl0"3, 0.758xl0" \ 0.827xl0"3, 0.896xl0" 3, 0.965xl0 ~ 3, 1.034x 10 ~ 3, 1.103xl0"3, 1.172xl0 ~ 3 and 0.0689-1.241xl0 ~ 3 MPa (10, 20, 30, 40, 50, 60, 70, 80, 90, 100, 110, 120, 130, 140, 150, 160, 170, and 180 milli-ft. -lb / sq. In).
Although not particularly limited, in one embodiment, a single layer can have an internal bond of 0.0689-1.241xl0"3 MPa (10-180 milli-ft-lb / sq in) as measured by the TAPPI 541 method. includes all values and subintervals between them including 0.069xl0 ~ 3, 0.138xl0 ~ 3, 0.207xl0"3, 0.276xl0 ~ 3, 0.345xl0 ~ 3, 0.414 x 10 ~ 3, 0.483xl0 ~ 3, 0.552xl0 ~ 3 , 0.621xl0 ~ 3, 0.689xl0 ~ 3, 0.758xl0 ~ \ 0.827xl0 ~ 3,
0. 896xl0'3, 0.965xl0"3, 1.034x 10" 3, 1.103xl0"3, 1.172xl0" 3 and 0.0689-1.241xl0"3 MPa (10, 20, 30, 40, 50, 60, 70, 80, 90 , 100, 110, 120, 130, 140, 150, 160, 170, and 180 milli-ft.-lb / sq. In).
Although not particularly limited, in one embodiment, one or more layers may have an internal bond or bonds greater than 1,241xl0-3 MPa (180 milli-ft-lb / sq in) as measured by the TAPPI 541 method. For example, all except one layer on a multilayer paper substrate may have internal joints greater than 1241x10 ~ 3 MPa (180 milli-ft-lb / sq in) as measured by the TAPPI 541 method. These intervals include all values and subintervals
among them for example greater than 1,241, 1,248, 1,262, 1,276, 1,289, 1303, 1,310, 1,379, 1,448, 1,517, 1,724 MPa (180, 181, 183, 185, 187, 189, 190, 200, 210, 220, 250 milli-ft.-lb / sq. in), and higher as measured by the TAPPI 541 method.
Although not particularly limited, in one embodiment, the adhesive bonding two layers together can have an internal bond greater than 1,241xl0"3 MPa (180 milli-ft-lb / sq in) as measured by the TAPPI 541 method. In another embodiment, one or more of one or all of the adhesive bonding the respective layers together may have an internal bond or bonds greater than 1,241xl0 ~ 3 MPa (180 milli-ft-lb / sq in) as measured by the TAPPI method 541. These intervals include all values and sub-ranges among them, for example greater than 1,241, 1,248, 1,262, 1,276, 1,289, 1,303, 1,310, 1,379, 1,448, 1,517, 1,724 MPa (180, 181, 183, 185, 187, 189, 190, 200, 210, 220, 250 milli-ft. -lb / sq. In), and higher as measured by the TAPPI 541 method.
Although not particularly limited, in one embodiment, the adhesive, a single layer, or both may have an internal bond or bonds greater than 1,241xl0 ~ 3 MPa (180 milli-ft-lb / sq in) as measured by the method TAPPI 541 Although not particularly limited, in one embodiment, one or more sides of the paper substrate may have a Taber abrasion of 50-200 mg, as measured by a method
modified TAPPI 476 om-? ß. This range includes all values and subintervals among them, including 50, 60, 70, 80, 90, 100, 110, 120, 130, 140, 150, 160, 170, 180, 190, and 200 mg. The Tappi method is modified as follows: 1.0 kg of dead weight in each arm; CS-10P abrasion wheels from Taber Industries; 100 revolutions; "mg" is weight loss in mg per 100 revolutions. Taber abrasion and methods to achieve it and measure it on paper substrate surfaces is shown. For example, in one embodiment, one or both sides of the paper substrate can be sanded or abraded according to known methods to quantify the desired Taber abrasion. In another embodiment, the paper substrate may include a layer, or an adhesive bonding two layers together, or a combination thereof which, upon peeling, results in a new exposed side having the desired Taber abrasion.
In one embodiment, when considering a surface that leads to fluff generation and corresponding good molding bond (good adhesion of the surface of the paper substrate to the binder in the joint compound), long fibers, as opposed to short fibers can be used in one or both of the outer layers. Long fibers provide more surface area for contact with the binder in the sludge from laminated gypsum board or in joint compound. In one embodiment, the fibers are not overrefined, since
High refining levels result in more fiber-to-fiber bonding. More bonding may be associated with greater difficulty in generating fluff (ie a stronger surface region). In one embodiment, wet pressing can be minimized or completely eliminated, which consolidates the wet surface and leads to higher levels of hydrogen bonds (ie, increased surface resistance). In one embodiment, the use of wet strength additives is minimized. In one embodiment, the use of additives or resistance binders applied on the surface (eg, starch) is minimized.
In one embodiment, the recently exposed side produced upon detachment of the substrate is suitable as a working side.
Although not particularly limited, in one embodiment, the paper substrate may have a side wall with a Taber abrasion of 50-200 mg. In another embodiment, the paper substrate may have a working side with a Taber abrasion of 50-200 mg. In another embodiment, the paper substrate can have both working and wall sides with respective Taber abrasions of 50-200 mg. Wall and working sides may have the same or different Taber abrasions. These ranges include all values and subintervals between them, including 50, 60, 70, 80, 90, 100, 110, 120, 130, 140, 150, 160, 170, 180, 190, and 200 mg.
In one embodiment, the working and / or wall sides may include additives to improve lint generation during sanding. For example, wax can be added to these layers for a fluffier and longer after sanding. In another embodiment, the working and / or wall sides may include components rich in binder, which may allow expensive binder to be removed from the gypsum board joint compound.
Although not particularly limited, in one embodiment, the paper substrate can have a wet tensile strength of 0.565-6.779 Nm (5-60 lbf / in) in width after impregnation in distilled water for 60 sec at 23 °. C. This range includes all values and sub-ranges among them, including 0.565, 1.130, 1.695, 2.260, 2825, 3889, 3.954, 4.519, 5.084, 5.649 / 6.214 and 6.779 Nm (5, 10, 15, 20, 25, 30, 35 , 40, 45, 50, 55, and 60 lbf / in) in width after impregnation in distilled water for 60 sec at 23 ° C. The wet tensile strength after impregnation can be conveniently measured by a modified TAPPI 456 method. The measurement is modified as follows: if the tensile strength of the paper substrate is measured before it is completely saturated, the results thus obtained are identified as "tensile strength after impregnation in water by ... (time) "... these results shall be distinguished from" MD tensile strength in
wet "as defined in the TAPPI 546 method. For the present purposes, the term impregnate is interpreted as submerging or submersion.
Although not particularly limited, in one embodiment, the paper substrate may have a caliber of 0.0127-0.02794 cm (0.005-0.011 in). This range includes all the values and subintervals between them, including 0.0127, 0.01524, 0.01778, 0.02032, 0.02286, 0.0254 and 0.02794 cm (0.005, 0.006, 0.007, 0.008, 0.009, 0.010, and 0.011 in). In one embodiment, the gauge can be obtained by compression, abrasion, heating or drying of the weft obtained from a laying process by air or any combination thereof.
As long as the paper substrate has at least two layers, the number of layers is not particularly limited. In one embodiment, the paper substrate may have 2 to 11 or more layers. This range includes all values and subranges between them, including 2, 3, 4, 5, 6, 7, 8, 9, 10, 11, and more layers. In one embodiment, the paper substrate has 3 to 7 layers. In another embodiment, the paper substrate has 3 to 5 layers. In another embodiment, the paper substrate has a maximum of three layers.
Although not limited in particular, in one embodiment, one layer or layers may include one or more of cellulose fibers, pulp fibers, synthetic fibers,
recycled fibers, virgin fibers or any combination thereof. In one embodiment, recycled fibers differ from virgin fibers in that they have previously been used in a paper product. In one embodiment, recycled fibers can be recycled cellulose, synthetics or any combination thereof. In one embodiment, the term "cellulose fibers" includes both cellulose and pulp fibers. The composition of one layer or layers may be the same or different than that of any other layer or layers.
Non-limiting examples of synthetic fibers include polyester and polyethylene terephthalate, polybutylene terephthalate, copolyethylene-butylene terephthalate, copolyethersethers, polyolefins, polyethylene, polypropylene, copolyethylene-propylene, nylon, polyacetate; polyvinyl acetate; rayon, polyvinyl chloride, copolymers of any of the foregoing, mixtures of any of the foregoing, combinations of any of the foregoing. In one embodiment, the synthetic fiber can conveniently be used as a binder or all or part of the adhesive.
In one embodiment, the synthetic fiber includes a so-called bi-component fiber, for example, one in which a fiber includes two polymers, one having a low melting temperature disposed towards the outside of the fiber, and one having a higher melting temperature
disposed towards the interior of the fiber. In one embodiment, the bi-component fiber includes a core of polypropylene or polyethylene terephthalate and a polyethylene sheath or sheath. In one embodiment, the synthetic fiber can conveniently be used as a binder or all or part of the adhesive. Non-limiting examples of bi-component or other fibers include those available from FiberVisions Corp. in Duluth, GA, in the USA, and Trevira GmbH in Bobingen, Germany, for example.
In one embodiment, at least one layer in the multi-layer paper substrate comprises cellulose fibers. In another embodiment, at least one layer in the multilayer paper substrate comprises cellulose fibers, wherein a majority of the fibers in that layer are cellulose. In one embodiment, the multi-layer paper substrate comprises a combination of cellulose fibers and synthetic fibers.
In one embodiment, the multilayer paper substrate may contain 0-100% by weight of cellulose fibers, based on the total weight of the substrate. That interval includes all values and subintervals between them, including 0, 1, 5, 10, 15, 20, 25, 30, 35, 40, 45, 50, 55, 60, 65, 70, 75, 80, 85, 90, 95 99, and 100% by weight. In one embodiment, the multilayer paper substrate contains from 30 to 99% by weight of cellulose fibers.
In one modality, one layer or more than one layer in the
Multilayer paper substrate, may contain 0-100% by weight of cellulose fibers based on the total weight of the layer or layers. This range includes all values and subintervals between them, including 0, 1, 5, 10, 15, 20, 25, 30, 35, 40, 45, 50, 55, 60, 65, 70, 75, 80, 85, 90, 95 99, and 100% by weight based on the weight of the layer.
Although not particularly limited, cellulose fibers can come from any source. In one embodiment, cellulose fibers include natural fibers, softwood, hardwood, straw; of pulp of plants and grass, cotton, other cellulose fibers and the like or a combination thereof.
In one embodiment, the multilayer paper substrate can contain 0-100% by weight of synthetic fibers based on the total weight of the substrate. That interval includes all values and subintervals among them including 0, 1, 5, 10, 15, 20, 25, 30, 35, 40, 45, 50, 55, 60, 65, 70, 75, 80, 85, 90 , 95 99, and 100% by weight.
In one embodiment, one layer or more than one layer in the multilayer paper substrate may contain 0-100% by weight of synthetic fibers based on the total weight of the layer or layers. This range includes all values and subintervals between them, including 0, 1, 5, 10, 15, 20, 25, 30, 35, 40, 45, 50, 55, 60, 65, 70, 75, 80, 85, 90, 95, 99 and 100% by weight, based on the weight of the layer.
Any or all of the layers in the multilayer paper substrate may include a combination of cellulose or synthetic fibers. For example, in one embodiment, the synthetic fiber can function as the binder, adhesive or both. In one embodiment, cellulose fibers and synthetics may be present in any weight range between them. This range is not particularly limited and may include, for example, weight proportions of synthetic cellulose fibers of 100: 0, 99: 1, 95: 5, 90:10, 85:15, 80:20, 75:25, 70 : 30, 65:35, 60:40, 55:45, 50:50, 45:55, 40:60, 35:65, 30:70, 25:75, 20:80, 15:85, 10:90 , 5:95, 1:99, and 0: 100.
In one embodiment, one or more layers of the multilayer paper substrate may have 99% by weight of bicomponent fibers, but the multilayer paper substrate has > 30% by weight of cellulose or pulp fibers.
In one embodiment, one or more layers may include > 70% by weight of synthetic fibers, and can be conveniently produced using spunbond or meltblown bonding technology.
The term "hardwood" as used herein, includes fibers or fibrous pulp derived from the wood substance of deciduous trees (angiosperms) such as birch, oak, beech, maple, and eucalyptus, or combinations thereof. The expression "soft wood" as
may be employed herein, includes fibrous pulps or fibers derived from the woody substance of coniferous trees (gymnosperms) such as varieties of spruce, spruce and pine such as for example taeda pine, slash pine, Colorado spruce, balsam fir; Douglas fir, Oregon pine or Douglas fir. In some embodiments, at least a portion of the pulp fibers may be provided from non-woody herbaceous plants including but not limited to kenaf, hemp, jute, flax, sisal or abaca, although legal restrictions and other considerations may make the use of hemp and other sources of fibers something impractical or impossible. Either whitening fibers or bleaching can be used. Recycled fibers are also suitable for use.
In one embodiment, the cellulose fibers in one layer or layers may comprise 1 to 100% by weight of cellulose fibers that originate from pure wood based on the total weight of the cellulose fibers in the layer or layers. This range includes all values and subintervals among them, including 1, 5, 10, 15, 20, 25, 30, 35, 40, 45, 50, 55, 60, 65, 70, 75, 80, 85, 90, 95, 99, and 100% by weight based on the weight of the cellulose fibers in the layer or layers.
In one embodiment, the cellulose fibers in one layer or layers may comprise 1 to 100% by weight of cellulose fibers originating from softwood based on the total weight of the cellulose fibers in the layer or layers. East
range includes all values and sub-ranges among them including 1, 5, 10, 15, 20, 25, 30, 35, 40, 45, 50, 55, 60, 65, 70, 75, 80, 85, 90, 95, 99, and 100% by weight based on the weight of the cellulose fibers in the layer or layers.
In one embodiment, any or all of the layers in the multilayer paper substrate can have any weight ratio of hardwood to softwood fibers. This range is not particularly limited, and may include, for example, weight proportions of softwood fibers in a soft manner of 100: 0, 99: 1, 95: 5, 90:10, 85:15, 80:20, 75 : 25, 70:30, 65:35, 60:40, 55:45, 50:50, 45:55, 40:60, 35:65, 30:70, 25:75, 20:80, 15:85 , 10:90, 5:95, 1:99, and 0: 100.
In one embodiment, the multilayer paper substrate may include a release layer having an internal bond of 0.0689-1.241xl0"3 Mpa (10-180 milli-ft-lb / sq in) as measured by the TAPPI method 541. This interval includes all the values and subintervals among them including 0.069xl0"3, 0.138xl0 ~ 3, 0.207xl0" 3, 0.276x10"3, 0.345xl0" 3, 0.414xl0"3, 0.483xl0" 3, 0.552xl0 ~ 3, 0.621x10"
3, 0.689xl0"3, 0.758xl0" 3, 0.827xl0"3, 0.896xl0" 3, 0.965x
10"3, 1.034xl0" 3, 1.103xl0"3, 1.172xl0" 3 and 0.0689-1.241xl0"3
MPa (10, 20, 30, 40, 50, 60, 70, 80, 90, 100, 110, 120, 130, 140, 150, 160, 170, and 180 milli-ft. -lb / sq. In). In one embodiment, the release layer is that layer that
failure under normal or approximately normal applied stress to the sides of the multilayer paper substrate, resulting in delamination of the substrate on the layer.
In one embodiment, the delamination layer may have low levels (eg, less than 50% by weight) of binder, adhesive or a combination thereof. This range includes all values and subintervals between them, including less than 50, 45, 40, 35, 30, 25, 20, 15, 10, 9, 8, 7, 6, 5, 4, 3, 2, 1, and 0% by weight of the layer.
The cellulose fibers can be unrefined or refined or fibrillated or a combination thereof.
The length of the cellulose fibers is not particularly limited. In one embodiment, the cellulose fibers have a refined length of 0.5 to 5.0 mm LWAFL as measured by FQA. The terms, LWAFL and FQA are known. Weight-Average Fibers Length (LWAFL = Length Weighted Average Fiber Length) is measured by Fiber Quality Analysis (FQA = Fiber Quality Analysis). In one embodiment, this is carried out in an Optec device, as it is known. The aforementioned refined length includes all values and subintervals between them, including 0.5, 0.55, 0.6, 0.65, 0.7, 0.75, 0.8, 0.85, 0.9, 0.95, 1, 2, 3, 4, and 5.0 mm, or any combination thereof. In one embodiment, the range of refined fibers is 0.65 to 4.0 mm LWAFL as measured by FQA.
The length of synthetic fibers is not particularly limited. In one embodiment, the synthetic fibers have a length of 0.5 to 5.0 mm of LWAFL as measured by FQA. This range includes all values and subintervals between them, including 0.5, 0.55, 0.6, 0.65, 0.7, 0.75, 0.8, 0.85, 0.9, 0.95, 1, 2, 3, 4, and 5.0 mm, or any combination thereof . In one embodiment, the synthetic fibers are in the range of 0.65 to 4.0 mm of LWAFL as measured by FQA.
In one embodiment, the delamination layer may comprise high levels (e.g., 50% or greater by weight of fibers) of hardwood fibers. This range includes all values and subintervals between them, including 50, 55, 60, 65, 70, 75, 80, 85, 90, 95, 96, 97, 98, 99, and 100% by weight of fibers in the layer and superiors.
In one embodiment, the delamination layer may comprise low levels (eg, less than 50% by weight of fibers) of refined fibers or fibrillated fibers. This range includes all values and subintervals between them, including less than 50, 45, 40, 35, 30, 25, 20, 15, 10, 9, 8, 7, 6, 5, 4, 3, 2, 1, and 0% by weight of the fibers.
In one embodiment, the delamination layer may comprise any combination of binder, adhesive, fibers, cellulose fibers, hardwood fibers, softwood fibers, refined fibers, fibrillated fibers or fibers.
synthetic In another embodiment, delamination can occur within an adhesive region or between an adhesive and an attached layer. In this case, the internal bonding of the adhesive or the internal bond between an adhesive and an attached layer may be in the range of 0.0689-1.241xl0 ~ 3 Mpa (10-180 milli-ft-lb / sq in) as measured by the TAPPI method 541, and that includes all the values and subintervals among them, including 0.069xl0 ~ 3, 0.138xl0 ~ 3, 0.207xl0"3, 0.276xl0 ~ 3, 0.345xl0 ~ 3, 0.414xl0 ~ 3, 0.483xl0 ~ 3 , 0.552xl0 ~ 3, 0.621xl0"3, 0.689x 10 ~ 3, 0.758xl0" 3, 0.827xl0 ~ 3, 0.896xl0 ~ 3, 0.965xl0 ~ 3,
1. 034xl0 ~ 3, 1.103xl0 ~ 3, 1.172xl0"3 and 0.0689-1.24 lxl O-3 MPa
(10, 20, 30, 40, 50, 60, 70, 80, 90, 100, 110, 120, 130, 140, 150, 160, 170, and 180 milli-ft. -lb / sq. In).
In one embodiment, the multilayer paper substrate may include one or more resistive layers that do not delaminate or fail under normal or approximately normal applied stress to the sides of the multilayer paper substrate - e.g., delaminate or fail to stress greater than those in which it occurs with the delamination layer. In one embodiment, this is achieved by having a layer or layers with a bond or internal bonds greater than those of the delamination layer. As such, in one embodiment, the layer or layers that do not delaminate may have an internal union of > 0.0689-1.241xl0 ~ 3 Mpa (10-180 milli-ft-lb / sq in) as measured by the TAPPI method 541. This
interval includes all values and subranges between them, including > 0.069xl0 ~ 3, 0.138xlCT3, 0.207xl0 ~ 3,
0. 276xl0"\ 0.345xl0" 3, 0.414xl0"3, 0.483xl0 ~ 3, 0.552xl0 ~ 3,
0. 621xl0 ~ 3, 0.689xl0 ~ 3, 0.758xl0 ~ 3, 0.827xl0 ~ 3, 0.896x 10"3, 0.965xl0 ~ 3, 1.034xl0" 3, 1.103xl0"3, 1.172xl0 ~ 3 and 0.0689-1.241xl0- 3 MPa (10, 20, 30, 40, 50, 60, 70, 80, 90, 100, 110, 120, 130, 140, 150, 160, 170, and 180 milli-ft. -lb / sq. In) In another embodiment, the layer or layers that do not delaminate may have an internal bond or bonds greater than 1,241xl0 ~ 3 Mpa (180 milli-ft-lb / sq in) as measured by the TAPPI 541 method. This range includes all values and subintervals among them, for example greater than 1,241, 1,248, 1,262, 1,276, 1,289, 1,303, 1,310, 1,379, 1,448, 1,517, 1,724 MPa (180, 181, 183, 185, 187, 189, 190, 200 , 210, 220, 250 milli-ft. -lb / sq. In), and higher as measured by the TAPPI 541 method.
In one embodiment, the strength layer may comprise any combination of binder, adhesive, fibers, cellulose fibers, hardwood fibers, softwood fibers, refined fibers, fibrillated fibers or synthetic fibers.
In one embodiment, the resistance layer (s) can have high levels (eg, greater than 50% by weight) of binder, adhesive or a combination thereof. This interval includes all values and
sub-ranges among them, including greater than 50, 55, 60, 65, 70, 75, 80, 85, 90, 95, 96, 97, 98, 99% by weight of the layer.
In one embodiment, the resistance layer (s) can comprise high levels (eg, 50% or greater by weight of fibers) of soft wood fibers. This range includes all values and subintervals between them, including 50, 55, 60, 65, 70, 75, 80, 85, 90, 95, 96, 97, 98, 99, and 100% by weight of fibers in the layer and superiors.
In another embodiment, the resistance layer (s) can comprise high levels (eg, greater than 50% by weight of fibers) of refined fibers or fibrillated fibers. This range includes all values and subintervals among them, including greater than 50, 55, 60, 65, 70, 75, 80, 85, 90, 95, 96, 97, 98, 99, and 100% by weight of the fibers .
In one embodiment, the cellulose fibers include unrefined southern softwood having lengths in the range of 3.0 to 5.0 rare.
In one embodiment, the cellulose fibers include heavily refined southern softwood having lengths in the range of 2.0 to 4.0 mm.
In one embodiment, the cellulose fibers include unrefined northern softwood having lengths in the range of 3.0 to 4.0 mm.
In one embodiment, cellulose fibers include
Northern soft wood strongly refined having lengths in the range of 1.0 to 5.0 mm.
In one embodiment, the cellulose fibers include unrefined hardwood having lengths in the range of 0.7 to 1.8 mm.
In one embodiment, the cellulose fibers include refined hardwood having lengths in the range of 0.5 to 1.5 mm.
In one embodiment, the cellulose fibers include refined softwood having lengths in the range of 1.0 to 5.0 mm. In one embodiment, the cellulose fibers include refined hardwood having lengths in the range of 0.5 to 1.8 mm.
In another embodiment, the resistance layer (s) can have one or more of tensile strength MD, tensile strength CD, wet tensile strength when impregnated or any combination thereof, which is higher than that of the delamination layer.
In one embodiment, at least one layer comprises fibers of which at least a majority are hardwood fibers.
In one embodiment, at least one layer comprises fibers of which at least a majority are soft wood fibers.
Provided that the base weight of the paper substrate of
multiple layers is 80-200 gsm, the base weights of the individual layers and adhesive regions are not particularly limited. For example, in a modality, a single layer can have a basis weight of 0.5-180 gsm, which includes all values and subintervals including 0.5, 1, 2, 3, 4, 5, 6, 7, 8, 9 , 10, 15, 20, 25, 30, 35, 40, 45, 50, 75, 85, 95, 100, 120, 140, 160, and 180 gsm.
In one embodiment, the paper substrate may include three layers arranged in the following order:
a layer comprising a basis weight of 5-100 gsm;
a layer comprising a basis weight of 5-65 gsm; and a layer comprising a basis weight of 5-100 gsm.
In one embodiment, the paper substrate may include four layers and the fourth layer may have a basis weight of 30-100 gsm.
In one embodiment, the paper substrate may include a third layer and be arranged in the following order: a layer comprising a basis weight of 30-100 gsm;
a layer comprising a basis weight of 5-65 gsm; and a layer comprising a basis weight of 30-100 gsm.
In one embodiment, the paper substrate may include four layers arranged in the following order:
a layer comprising a basis weight of 30-100 gsm;
a layer comprising a basis weight of 5-65 gsm;
a layer comprising a basis weight of 5-50 gsm; Y
a layer comprising a basis weight of 30-100 gsm.
In one embodiment, the paper substrate can be arranged in the following order:
a layer comprising a basis weight of 5-100 gsm;
the adhesive in an amount of 0.05-10 gsm; Y
a layer comprising a basis weight of 5-100 gsm.
In one embodiment, the paper substrate may include a third layer, the third layer comprising a basis weight of 30-100 gsm.
In one embodiment, the paper substrate may include three layers arranged in the following order:
a layer comprising a basis weight of 30-100 gsm;
the adhesive in an amount of 0.05-10 gsm;
a layer comprising a basis weight of 5-50 gsm; and a layer comprising a basis weight of 30-100 gsm.
In one embodiment, the paper substrate may include three layers arranged in the following order:
a layer comprising an MD tensile strength of 2.26-33,895 Nm (20-300 lbf / in) in width as measured by the TAPPI method 494 and / or a CD tensile strength of 1.13-33,895 Nm (10-6). 300 lbf / in) in width as measured by the TAPPI method 494;
a layer comprising an internal bond of 0.0689-1.241xl0"3 Mpa (10-180 milli-ft-lb / sq in) as measured by the TAPPI 541 method;
a layer comprising an MD tensile strength of 2.26-33,895 Nm (20-300 lbf / in) in width as measured by the TAPPI method 494 and / or a CD tensile strength of 1.13-33,895 Nm (10 -300 lbf / in) in width as measured by the TAPPI 494 method.
In one embodiment, the paper substrate may include four layers arranged in the following order:
a layer comprising a Taber abrasion of 50-200 mg; a layer comprising an MD tensile strength of 2.26-33,895 Nm (20-300 lbf / in) wide as measured by the TAPPI method 494 and a CD tensile strength of 1.13-33,895 Nm (10-300 lbf / in) wide as measured by the TAPPI method 494;
a layer comprising an internal bond of 0.0689-1.241xl0"3 Mpa (10-180 milli-ft-lb / sq in) as measured by the TAPPI 541 method;
a layer comprising a Taber abrasion of 50-200 mg.
In one embodiment, the paper substrate may include five layers arranged in the following order:
a layer comprising a Taber abrasion of 50-200 mg; a layer comprising an MD tensile strength of 1.13-33.895 Nm (10-300 lbf / in) in width as measured by the TAPPI method 494 and / or a CD tensile strength of 1.13-33.895 Nm (10-6). 300 lbf / in) in width as measured by the TAPPI method 494;
a layer comprising an internal junction of 0.0689-1.241xl0"3 Mpa (10-180 milli-ft-lb / sq in) as measured by the TAPPI 541 method;
a layer comprising an MD tensile strength of 1.13-33.895 Nm (10-300 lbf / in) in width as measured by the TAPPI method 494 and / or a CD tensile strength of 1.13-33.895 Nm (10-6). 300 lbf / in) in width as measured by the TAPPI method 494; Y
a layer that has a Taber abrasion of 50-200 mg.
In one embodiment, the paper substrate can be arranged in the following order:
a layer comprising an MD tensile strength of 2.26-33.895 Nm (20-300 lbf / in) wide as measured by the TAPPI 494 method and / or CD tensile strength of 1.13-33.895 Nm (10-300) lbf / in) in width as measured by the TAPPI method 494;
the adhesive, which comprises an internal bond of 0.0689-1.241xl0 ~ 3 Mpa (10-180 milli-ft-lb / sq in) as measured by the TAPPI 541 method; Y
a layer comprising an MD tensile strength of 2.26-33,895 Nm (20-300 lb £ / in) wide as measured by the TAPPI method 494 and / or a CD tensile strength of 1.13-33,895 Nm ( 10-300 lbf / in) in width as measured by the TAPPI 494 method.
In one embodiment, the paper substrate can
Include three layers arranged in the following order:
a layer comprising a Taber abrasion of 50-200 mg; a layer comprising an MD tensile strength of 2.26-33,895 Nm (20-300 lbf / in) wide as measured by the TAPPI 494 method and a CD tensile strength of 1.13-33,895 Nm (10-300 lbf) / in) wide as measured by the TAPPI method 494;
the adhesive, which comprises an internal bond of 0.0689-1.241xl0 ~ 3 Mpa (10-180 milli-ft-lb / sq in) as measured by the TAPPI 541 method; Y
a layer comprising a Taber abrasion of 50-200 mg.
In one embodiment, the paper substrate may include four layers arranged in the following order:
a layer comprising a Taber abrasion of 50-200 mg; a layer comprising an MD tensile strength of 2.26-33.895 Nm (20-300 lbf / in) wide as measured by the TAPPI 494 method and / or CD tensile strength of 1.13-33.895 Nm (10-300) lbf / in) in width as measured by the TAPPI method 494;
the adhesive, which comprises an internal bond of 0.0689-1.241x10"3 Mpa (10-180 milli-ft-lb / sq in) as measured by the TAPPI 541 method;
a layer comprising an MD tensile strength of 2.26-33,895 N-m (20-300 lbf / in) in width as measured by the TAPPI method 494 and / or a CD tensile strength of
1. 13-33,895 N-m (10-300 lbf / in) in width as measured by the TAPPI 494 method; Y
a layer that has a Taber abrasion of 50-200 mg.
In one embodiment, the paper substrate may include three layers arranged in the following order:
a layer comprising a basis weight of 30-100 gsm;
the adhesive in an amount of 0.05-10 gsm;
a layer comprising a basis weight of 5-50 gsm; and a layer comprising a basis weight of 30-100 gsm.
In one embodiment, the paper substrate may include four layers arranged in the following order:
a layer comprising a basis weight of 30-100 gsm;
a layer comprising a basis weight of 5-50 gsm;
the adhesive in an amount of 0.05-10 gsm;
a layer comprising a basis weight of 5-50 gsm; and a layer comprising a basis weight of 30-100 gsm.
In one embodiment, the paper substrate may include five layers arranged in the following order:
a layer comprising a basis weight of 30-100 gsm;
a layer comprising a basis weight of 5-50 gsm;
a layer comprising a basis weight of 5-65 gsm;
a layer comprising a basis weight of 5-50 gsm; and a layer comprising a basis weight of 30-100 gsm.
In one embodiment, the layers arranged in a particular order may be joined together by one or more adhesives,
with or without an intermediate layer. In one embodiment, the adhesives that join attached layers together may be the same or different. In one embodiment, the adhesive comprises a binder, and the binder permeates all or part of the thickness of the multilayer paper substrate and bonds the layers together.
Although not particularly limited, the paper substrate can be cut to any width. In one embodiment, the paper substrate has a width of a reel of a paper machine of 38.1-254 cm (15-100 in), which includes all values and subranges therebetween, including 38.1, 63.5, 127, 190.5 and 254 cm (15, 25, 50, 75, and 100 in).
Although not particularly limited, the paper substrate can be cut to any width. In one embodiment, the paper substrate can be cut to a width of 2.54-8.255 cm (1.0-3.25 in), which includes all values and subintervals between them, including 2.54, 3.81, 4.445, 5.08, 6.35, 6.985, 7.62 and 8.255 cm (1.0, 1.5, 1.75, 2, 2.5, 2.75, 3, and 3.25 in).
Although not particularly limited, the multilayer paper substrate is particularly suitable for use as a tape for drywall joints. In one embodiment, the multilayer paper substrate can be cut to a suitable width to be used as a tape for plaster paper joints. Gypsum paper tape can be used
be conveniently applied to a joint, corner, opening, hole, depression, screw, nail, defect or the like in a gypsum panel, sometimes also referred to as "laminated gypsum board or cardboard or PYL" according to well-known methods . In a form however, where the installer wishes to remove a portion of the tape thus applied, the tape can be easily peeled (delaminated) by applying normal or approximately normal tension to the wall or side of the tape. The drywall tape will delaminate either on a layer, a region of adhesive or between a region of adhesive and a layer. A portion of the tape remains on the wall and in one embodiment, a new work surface is presented. The installer can then apply more laminated gypsum board joint compound to the newly exposed surface, separate it, sand it, apply more tape, paint or any combination thereof, to effect the repair.
As such, in one embodiment, a method for installing or repairing gypsum board includes contacting a gypsum board surface with the paper substrate or gypsum board bonding tape described herein. In another embodiment, the method includes detaching the paper substrate or the plasterboard binding tape by separating them, wherein only one layer delaminates. In another modality, the method
includes detaching the substrate, where the adhesive delaminates.
The multi-layer paper substrate can be conveniently produced by an airway process.
In one embodiment, the multilayer paper substrate comprises one or more outer sides sanded or subjected to abrasion, perforation, notching, grooving or any combination thereof.
One embodiment of the subject matter claimed herein provides a method for producing the multilayer paper substrate, comprising:
using a papermaking machine placed by air, forming at least two layers, contacting one or both of the layers with an adhesive and contacting the layers together to form a two-layer web; Y
compress the two-layer plot to produce the paper substrate.
The processes of placement by air are known in general. Non-limiting examples of airway placement processes can be found in U.S. Patents. Nos. 2,624,079, 3,825,381, 3,895,089, 4,141,772, 4, 370, 289, for example, all the contents of each of which are incorporated herein by reference.
In one modality, in the placement machine by
by air, fibers are trapped in one or more air streams and direct on a moving forming wire, cloth or support or the like. One or more layers of fibers in this way are applied and constructed or accumulated in a layer-like manner in the forming wire or fabric. The type and composition of the fibers and layers can conveniently be controlled according to known methods. One or more adhesives may be applied in any convenient manner to one or both sides of a layer, between layers or the like as the layers are directed onto the forming wire, after which a layer is directed to the forming wire, the screen or their combinations. In one embodiment, the adhesive can be mixed, for example, as a powder or other solid, with the fibers as they are trapped in the air stream, or before they are caught in the air stream, or any combination thereof. In one embodiment, the adhesive may comprise a binder or be in the form of a binder that is applied to the weft.
One embodiment of a papermaking machine with aerial placement is shown in Figure 6. The fibers obtained in the Kamas mill (hammer mill) travel to one or more of the input box layers 1-4 and deposit or place by air on the moving wire or cloth near one or more suction boxes. If desired, one or more adhesives can be applied at the exits of
adhesive, which may be a spray box, spray bar, powder spout or the like. The layers combine to form a web, which is compressed in the press. The compressed web may travel to a drying section, and one or more additives may optionally be added. Further drying can be carried out in the drying section, and the multilayer paper substrate is collected in a winder. The drying temperature is not particularly limited and can be conveniently selected as appropriate.
One embodiment of an airway entry box is shown in Figure 7. The rotary cylinder may include a cleaning brush and a defibrizer. The cleaning brush can clean the holes for the fiber, so that the fibers can be deposited from the rotating cylinder on the motion wire without clogging. The orifice size is not particularly limited and can have any suitable range for the size of the fibers to be deposited.
In one embodiment, the formation of the two layers at least and the contact of one or both of the layers with an adhesive can occur in any order. For example, the fibers can be contacted with an adhesive before they are formed into layers. In another embodiment, the fibers can be contacted with an adhesive at the same time that they are
they form in layers. In another embodiment, the fibers may be contacted with an adhesive after being formed into layers.
In another embodiment, the fibers may be contacted with an adhesive with any combination before being formed into layers, while forming in layers or after forming into layers.
The layers can be compressed to form the substrate. Of course, as long as there are at least two layers, the number of compressed layers is not particularly limited. In one embodiment, the number of layers resulting in the multilayer paper substrate will be the same as the number of layers in the screen. In this way, at least in part, and optionally combined with the selection and application of adhesive, the properties of each layer and / or the multilayer paper substrate can be controlled.
The layers, weft, substrate or any combination thereof may be further treated. For example, in one embodiment, one or more of the layers, the web, the substrate or any combination thereof may be heated, contacted with a binder or the like or any combination thereof.
The adhesive form is not limited in particular. It can be in the form of a solid, powder, liquid, melt or a combination thereof. Non-limiting examples of adhesive include starch, thermoplastic polymer, polymer
thermoplastic elastomer, blended polymer, bicomponent polymer, solution, dispersion, emulsion, latex or the like or any combination thereof. In one embodiment, the adhesive may be a fiber or heat-sensitive polymer, which, when heated to a suitable temperature, for example a temperature near or above its melting temperature, will bond to fibers in a layer or layers. In one embodiment, the adhesive may be a pressure sensitive polymer or fiber, which when exposed to a suitable pressure will bond to fibers in a layer or layers. Electromagnetically sensitive adhesives, for example, which bind under UV, microwave, infrared, electron beam or similar electromagnetic radiation, can also be used.
The method may conveniently include one or more stages of wetting, spraying, application of water or the like to any of the layers, weft or substrate.
In one embodiment, the method includes one or more of sanding or abrading one or both of the outer surfaces or sides of the paper substrate, piercing the paper substrate, notching the paper substrate, slitting the paper substrate or any combination of the same.
In one embodiment, the method includes contacting a gypsum panel surface with the paper substrate or gypsum panel tape.
If desired, soft wood fibers and / or wood
hard can be modified in physical and / or chemical form. Examples of physical modification include but are not limited to electromagnetic and mechanical methods. Examples of electrical modification include but are not limited to those that involve contacting the fibers with a source of electromagnetic energy such as light and / or electric current. Examples of mechanical modification include but are not limited to those involving contacting an inanimate object with the fibers. Examples of these inanimate objects include those with sharp edges and / or blunt. These means also involve for example means for retinating, cutting, kneading, hitting, punching, etc.
Examples of chemical modification include but are not limited to those found in the following U.S. Patents. Numbers 6,592,717, 6,582,557, 6,579,415, 6,579,414, 6,506,282, 6,471,824, 6,361,651, 6,146,494, Hl, 704, 5,698,688, 5,698,074, 5,667,637, 5,662,773, 5,531,728, 5,443,899, 5,360,420, 5,266,250, 5,209,953, 5,160,789, 5,049,235, 4,986,882, 4,496,427, 4,431,481, 4,174,417 , 4,166,894, 4,075,136, and 4,022,965, which were hereby incorporated by reference in their entirety.
In one embodiment, all or part of the softwood fibers may optionally originate from softwood species that have a standard means
canadian ease of drainage or refining grade (CSF = Canadian Standard Freeness) from 300 to 750. In one embodiment, the fibers originate from a softwood species that has a CSF from 400 to 550. These ranges include any and all intermediate values and subintervals, for example 300, 310, 320, 330, 340, 350, 360, 370, 380, 390, 400, 410, 420, 430, 440, 450, 460, 470, 480, 490, 500, 510, 520, 530, 540, 550, 560, 570, 580, 590, 600, 610, 620, 630, 640, 650, 660, 670, 680, 690, 700, 710, 720, 730, 740, and 750 of CSF. The CSF is as measured by the TAPPI T-227 standard test.
In one embodiment, all or part of the hardwood fibers may optionally originate from hardwood species having a CSF from 300 to 750. In one embodiment, the fibers originate from hardwood species that have CSF values from 400 to 550. These ranges include 300, 310, 320, 330, 340, 350, 360, 370, 380, 390, 400, 410, 420, 430, 440, 450n, 460, 470, 480, 490, 500, 510, 520 , 530, 540, 550, 560, 570, 580, 590, 600, 610, 620, 630, 640, 650, 660, 670, 680, 690, 700, 710, 720, 730, 740, and 750 of CSF, and any and all intervals and subintervals there.
In one embodiment, one or more layers of the multilayer paper substrate further comprise one or more additives such as binders, sizing, latex, agent
Wet strength, dry strength agent, wax, wax emulsion, microspheres, expandable microspheres, polyvinyl alcohol, polyvinyl acetate, retention aid, filler, antifungal agent, mold inhibiting agent, thickener, preservative, clay, sulfate dehydrated calcium, calcium sulfate hemihydrate, calcium carbonate, precipitated calcium carbonate, silica, colloidal silica, silica sol, water, bleach, dye, pigment, optical brightening agent, wetting agent, bleaching agent, cationic wet strength agent , alkaline sizing agent, anionic promoter, other additive or a combination thereof. If present, the amount of additive is not particularly limited. In one embodiment, the additive may be present in amounts in the range of about 0.005 to about 50% by weight based on the weight of the layer. This range includes all values and subintervals between them, including approximately 0.005, 0.006, 0.007, 0.008, 0.009, 0.01, 0.02, 0.03, 0.04, 0.05, 0.06, 0.07, 0.08, 0.09, 0.1, 0.2, 0.3, 0.4, 0.5 , 0.6, 0.7, 0.8, 0.9, 1, 2, 3, 4, 5, 6, 7, 8, 9, 10, 15, 20, 25, 30, 35, 40, 45, and 50% by weight or any combination thereof, based on the weight of the layer.
In one embodiment, the multilayer paper substrate does not include one or more of a strength agent in
wet cationic, alkaline sizing agent or anionic promoter.
Examples of optional fillers include but are not limited to clay, calcium carbonate, calcium sulfate hemihydrate and calcium sulfate dihydrate, chalk or chalk, GCC, PCC, and the like.
Examples of optional binders include but are not limited to polyvinyl alcohol, Amres (one type of Kymene), Bayer Parez, polychloride emulsion, modified starch such as hydroxyethyl starch, starch, polyacrylamide, modified polyacrylamide, polyol, polyol carbonyl adduct, condensate ethanedial / polyol, polyamide, epichlorohydrin, glyoxal, glyoxal urea, etandial, aliphatic polyisocyanate, isocyanate, 1,6 hexamethylene diisocyanate, diisocyanate, polyisocyanate, polyester, polyester resin, polyvinyl acetate, polyacrylate, polyacrylate resin, acrylate and dimethacrylate. Other optional substances include but are not limited to silicas, such as colloids and / or sols. Examples of silicas include but are not limited to sodium silicate and / or borosilicates.
The composition may optionally include one or more pigments. Non-limiting examples of pigments include calcium carbonate, kaolin clay, calcined clay, aluminum trihydrate, titanium dioxide, talc, plastic pigment, crushed calcium carbonate, calcium carbonate
precipitate, amorphous silica, modified calcium carbonate, modified calcined clay, aluminum silicate, zeolite, aluminum oxide, colloidal silica, colloidal alumina slime, modified calcium carbonate, modified ground calcium carbonate, modified precipitated calcium carbonate or mix of them.
As used herein in their entirety, ranges are used as an abbreviated form to describe each and every one of the values that are within the range including all subintervals.
All other references, as well as their cited references, described herein, are incorporated herein by reference with respect to relative portions related to the subject of the present invention and all its modalities.
Numerous modifications and variations in the present invention are possible in light of the above teachings. Therefore, it will be understood that within the scope of the appended claims, the invention may be practiced otherwise than as specifically described herein.
Claims (22)
1. A multilayer paper substrate, characterized in that it comprises: at least two layers joined together by an adhesive; a base weight of 80-200 gsm; an internal union of 0.0689-1.241x10"3 Mpa (10-180 milli-ft-lb / sq in) as measured by the TAPPI 541 method, an MD tensile strength of 2.26-33.895 Nm (20-300 lbf / in) width as measured by the TAPPI 494 method, and a CD tensile strength of 1.13-33.895 Nm (10-300 lbf / in) wide as measured by the TAPPI 494 method.
2. The paper substrate according to claim 1, characterized in that it also comprises at least one side having a Taber abrasion of 50-200 mg.
3. The paper substrate according to claim 1, characterized in that it further comprises a wet tensile strength of 0.565-6.779 N-m (5-60 lbf / in) in width.
4. The paper substrate according to claim 1, characterized in that it comprises 3 to 7 layers.
5. The paper substrate according to claim 1, characterized in that at least one layer comprises fibers of which a majority are cellulose fibers.
6. The paper substrate according to claim 1, characterized in that the adhesive, a single layer or both comprise an internal junction of 0.0689-1.241x10 Mpa (10-180 milli-ft-lb / sq in) as measured by the TAPPI 541 method.
7. The paper substrate according to claim 1, characterized in that the adhesive, a single layer or both comprise an internal bond greater than 1,241xl0 ~ 3 Mpa (180 milli-ft-lb / sq in) as measured by the TAPPI method 541
8. The paper substrate according to claim 1, characterized in that one or more layers comprise: an MD tensile strength of 2.26-33.895 N-m (20-300 lbf / in) in width as measured by the TAPPI method 494; and a CD tensile strength of 1.13-33.895 N-m (10-300 lbf / in) wide as measured by the TAPPI 494 method.
9. The paper substrate according to claim 1, characterized in that it also comprises a third layer and arranged in the following order: a layer comprising a MD tensile strength of 2.26-33,895 Nm (20-300 lbf / in) in width as measured by the TAPPI method 494 and / or a CD tensile strength of 1.13-33.895 Nm (10-300 lbf / in) in width as measured by the TAPPI method 494; a layer comprising an internal bond of 0.0689-1.241xl0 ~ 3 Mpa (10-180 milli-ft-lb / sq in) as measured by the TAPPI 541 method; and a layer comprising a resistance to MD traction of 2.26-33.895 Nm (20-300 lbf / in) wide as measured by the TAPPI 494 method and / or a CD tensile strength of 1.13-33.895 Nm (10-300 lbf / in) wide as it is measured by the TAPPI 494 method.
10. The paper substrate according to claim 1, characterized in that it also comprises a third layer and arranged in the following order: a layer comprising a Taber abrasion of 50-200 mg; a layer comprising an MD tensile strength of 2.26-33,895 Nm (20-300 lbf / in) wide as measured by the TAPPI 494 method and a CD tensile strength of 1.13-33,895 Nm (10-300 lbf) / in) wide as measured by the TAPPI method 494; the adhesive, which comprises an internal bond of 0.0689-1.24 lxlO-3 Mpa .. (10-180 milli-ft-lb / sq in) as measured by the TAPPI 541 method; and a layer comprising a Taber abrasion of 50-200 mg.
11. The paper substrate according to claim 1, characterized in that it is produced by an air-laying process.
12. A plasterboard bonding tape comprising the paper substrate according to claim 1.
13. A method for installing or repairing gypsum board, comprising contacting a gypsum panel surface with the paper substrate in accordance with claim 1
14. The method according to claim 13, characterized in that it also comprises detaching by separating the paper substrate, where only one layer delaminates.
15. The method according to claim 13, characterized in that it also comprises detaching separating the substrate, where the adhesive delaminates.
16. A method for producing the paper substrate according to claim 1, characterized in that it comprises: using a processing machine with aerial positioning, forming at least two layers, contacting one or both of the layers with an adhesive, and in contact the layers together to form a two-layer web; and compressing a two-layer web to produce the paper substrate.
17. The method according to claim 16, characterized in that it further comprises heating one or both of the layers, the weft, the substrate or any combination thereof.
18. The method according to claim 16, characterized in that it further comprises contacting one or both of the layers, the weft, or both one or more of the layers and the weft with a binder.
19. The method in accordance with the claim 18, characterized in that the contact comprises applying the binder in solid form, in powder form, in liquid form, in the form of a melt or a combination thereof.
20. The method according to claim 16, characterized in that contacting the adhesive comprises applying the adhesive in solid form, powder form, liquid form, melt form or combination thereof.
21. The method according to claim 16, characterized in that it further comprises sanding or abrading one or more outer surfaces of the paper substrate.
22. The method according to claim 16, characterized in that it further comprises contacting a gypsum panel surface with the paper substrate.
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PCT/US2012/047332 WO2013013006A1 (en) | 2011-07-20 | 2012-07-19 | Substrate for wallboard joint tape and process for making same |
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MX2014000811A MX348087B (en) | 2011-07-20 | 2012-07-19 | Substrate for wallboard joint tape and process for making same. |
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MX2017006339A MX363218B (en) | 2011-07-20 | 2012-07-19 | Substrate for wallboard joint tape and process for making same. |
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- 2012-07-19 CN CN201610402945.5A patent/CN106087596B/en active Active
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CN106087596B (en) | 2019-01-22 |
US10106932B2 (en) | 2018-10-23 |
CN103703186B (en) | 2016-08-17 |
WO2013013006A1 (en) | 2013-01-24 |
EP2734674C0 (en) | 2023-06-07 |
MX363218B (en) | 2019-03-13 |
EP2734674B1 (en) | 2023-06-07 |
EP2734674A1 (en) | 2014-05-28 |
US20130087268A1 (en) | 2013-04-11 |
US9017803B2 (en) | 2015-04-28 |
AU2012284019B2 (en) | 2015-07-30 |
US20150211189A1 (en) | 2015-07-30 |
CA2841961A1 (en) | 2013-01-24 |
MX348087B (en) | 2017-05-24 |
ES2951258T3 (en) | 2023-10-19 |
BR112014001324A2 (en) | 2017-04-18 |
AU2012284019A1 (en) | 2014-02-13 |
CN103703186A (en) | 2014-04-02 |
CA2841961C (en) | 2021-01-26 |
CN106087596A (en) | 2016-11-09 |
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